Disassembly and Assembly

Transcription

1 K EN R August 2006 Disassembly and Assembly Industrial Engine M G A (Engine) MGB (Engine) M G D (Engine)

2 Important Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly. Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as DANGER, WARNING or CAUTION. The Safety Alert WARNING label is shown below. The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved. The message that appears under the warning explains the hazard and can be either written or pictorially presented. Operations that may cause product damage are identified by labels on the product and in this publication. Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method or operating technique that is not specifically recommended by Perkins is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose. The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Perkins dealers or Perkins distributors have the most current information available. When replacement parts are required for this product Perkins recommends using Perkins replacement parts. Failure to heed this warning can lead to premature failures, product damage, personal injury or death.

3 KENR Table of Contents Table of Contents Fuel Priming Pump - Remove and Install... 4 Fuel Filter Base - Remove... 4 Fuel Filter Base - Disassemble... 5 Fuel Filter Base - Assemble... 6 Fuel Filter Base - Install... 6 Fuel Transfer Pump - Remove... 7 Fuel Transfer Pump - Install... 7 Electronic Unit Injector - Remove... 8 Electronic Unit Injector - Install... 9 Electronic Unit Injector Sleeve - Remove Electronic Unit Injector Sleeve - Install Turbocharger - Remove Turbocharger - Install Exhaust Manifold - Remove and Install Exhaust Elbow - Remove and Install Inlet and Exhaust Valve Springs - Remove and Install Inlet and Exhaust Valves - Remove and Install Inlet and Exhaust Valve Guides - Remove and Install Engine Oil Filter Base - Remove Engine Oil Filter Base - Disassemble Engine Oil Filter Base - Assemble Engine Oil Filter Base - Install Engine Oil Cooler - Remove Engine Oil Cooler - Install Engine Oil Pump - Remove Engine Oil Pump - Disassemble Engine Oil Pump - Assemble Engine Oil Pump - Install Water Pump - Remove Water Pump - Install Water Temperature Regulator Housing - Remove and Install Engine Support (Front) - Remove and Install Flywheel - Remove Flywheel - Install Crankshaft Rear Seal - Remove Crankshaft Rear Seal - Install Flywheel Housing - Remove and Install Vibration Damper and Pulley - Remove and Install Crankshaft Front Seal - Remove Crankshaft Front Seal - Install Front Cover - Remove Front Cover - Install Gear Group (Front) - Remove Gear Group (Front) - Install Housing (Front) - Remove Housing (Front) - Install Crankcase Breather - Remove and Install (Open Breather) Valve Mechanism Cover - Remove and Install Rocker Arm and Shaft - Remove Rocker Arm - Disassemble Rocker Arm - Assemble Rocker Arm and Shaft - Install Cylinder Head - Remove Cylinder Head - Install Camshaft - Remove Camshaft - Install Camshaft Gear - Remove and Install Camshaft Bearings - Remove Camshaft Bearings - Install Engine Oil Pan - Remove and Install Cylinder Liner - Remove Cylinder Liner - Install Piston Cooling Jets - Remove and Install Pistons and Connecting Rods - Remove Pistons and Connecting Rods - Disassemble Pistons and Connecting Rods - Assemble Pistons and Connecting Rods - Install Connecting Rod Bearings - Remove (Connecting rods in position) Connecting Rod Bearings - Install (Connecting rods in position) Crankshaft Main Bearings - Remove Crankshaft Main Bearings - Install Crankshaft - Remove Crankshaft - Install Bearing Clearance - Check Atmospheric Pressure Sensor - Remove and Install Camshaft Position Sensor - Remove and Install.. 81 Crankshaft Position Sensor - Remove and Install Coolant Temperature Sensor - Remove and Install Engine Oil Pressure Sensor - Remove and Install Fuel Temperature Sensor - Remove and Install Inlet Manifold Temperature Sensor - Remove and Install Inlet Manifold Pressure Sensor - Remove and Install Belt Tightener - Remove Belt Tightener - Install Fan - Remove and Install Fan Drive - Remove Fan Drive - Install Pump Drive - Remove (Transfer pump) Pump Drive - Disassemble (Transfer pump) Pump Drive - Assemble (Transfer pump) Pump Drive - Install (Transfer pump) Electronic Control Module - Remove and Install Alternator - Remove and Install Electric Starting Motor - Remove and Install Index Section Index... 97

4 4 KENR6232 Disassembly and Assembly Section i FuelPrimingPump-Remove and Install Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates. 1. Turn the fuel supply to the OFF position. Illustration 2 1. Position a new joint (3) on fuel filter base (4). Note: Ensure correct orientation of the joint. g Position the fuel priming pump assembly (1) on the fuel filter base and install bolts (2). Tighten the 1/4" bolt to a torque of 12 N m (105 lb in). Tighten the5/16"bolttoatorqueof25n m(221lbin). 3. Turn the fuel supply to the ON position. 4. Remove the air from the system. Refer to Systems Operation, Testing and Adjusting, Fuel System - Prime. Fuel Filter Base - Remove i Illustration 1 2. Remove bolts (2). Remove fuel priming pump assembly (1) from fuel filter base (4). 3. Remove joint (3) from the fuel priming pump assembly and the fuel filter base. g Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates.

5 KENR Turn the fuel supply to the OFF position. i Fuel Filter Base - Disassemble Disassembly Procedure Start By: a. Remove the fuel filter base. Refer to Disassembly and Assembly, Fuel Filter Base - Remove. Illustration 3 g Place a suitable container below the fuel filter base in order to drain the fuel from the fuel filter assemblies (10) and (12). 3. Remove plugs (9) and (11). Allow the fuel to drain. 4. Disconnect harness assembly (1) from fuel temperature sensor (2). Note: In order to disconnect the harness assembly, slide the locking tab into the unlocked position. 5. Disconnect hose assembly (3). Disconnect hose assembly (5). Disconnect hose assemblies (7) and (8). Plug the open hose assemblies. 6. Useasuitabletoolwitha1/2"squaredrive in order to remove fuel filter assemblies (10) and (12). Remove the O-ring seals. Remove the fuel filter elements. Refer to Operation and Maintenance Manual, Fuel Filter - Replace for more information. 7. Remove bolts (4). Remove fuel filter base (6). Illustration 4 g Remove fuel priming pump (4) from fuel filter base assembly (1). Refer to Disassembly and Assembly, Fuel Priming Pump - Remove and Install. 2. Remove fuel temperature sensor (2) from fuel filter base assembly (1). Refer to Disassembly and Assembly, Fuel Temperature Sensor - Remove and Install. 3. Remove fuel bypass valve (6) from fuel filter base assembly (1). Remove the O-ring seals from the fuel bypass valve. 4. Remove fuel check valve (10) from fuel filter base assembly (1). Remove the O-ring seals from the fuel check valve. 5. Remove connections (3), (5), (7) and (8) from fuel filter base assembly (1). Remove the O-ring seals from the connections. 6. Remove plugs (9), (11) and (12) from fuel filter base assembly (1). Remove the O-ring seals from the plugs.

6 6 KENR6232 i Fuel Filter Base - Assemble Assembly Procedure 6. Install fuel temperature sensor (2) to fuel filter base assembly (1). Refer to Disassembly and Assembly, Fuel Temperature Sensor - Remove and Install. 7. Install fuel priming pump (4) to fuel filter base assembly (1). Refer to Disassembly and Assembly, Fuel Priming Pump - Remove and Install. End By: a. Install the fuel filter base. Refer to Disassembly and Assembly, Fuel Filter Base - Install. 1. Ensure that the filter base is clean and free from damage. If necessary, replace the filter base. Fuel Filter Base - Install i Illustration 5 g Install new O-ring seals to plugs (9), (11) and (12). Install the plugs to fuel filter base assembly (1). Tighten plug (9) to a torque of 41 N m (30 lb ft). Tighten plugs (11) and (12) to a torque of 15 N m (11lbft). 3. Install new O-ring seals to connections (3), (5), (7) and (8). Install the connections to fuel filter base assembly (1). Tighten connections (3), (5) and (7) toatorqueof15n m(11lbft).tightenconnection (8)toatorqueof41N m(30lbft). Note: Ensure correct orientation of the connections. 4. Install new O-ring seals to fuel bypass valve (6). Install the fuel bypass valve to fuel filter base assembly (1). Tighten fuel bypass valve (6) to a torque of 35 N m (26 lb ft). Illustration 6 g Install new O-ring seals to fuel check valve (10). Install the fuel check valve in fuel filter base assembly (1). Tighten the fuel check valve to a torque of 35 N m(26 lb ft). 1. Position fuel filter base (6) and install bolts (4). Tighten the bolts to a torque of 47 N m (35 lb ft). 2. Install new O-ring seals and new fuel filter elements to fuel filter assemblies (10) and (12). Use a suitable tool with a 1/2" square drive in order to install the fuel filter assemblies.

7 KENR Install new O-ring seals to plugs (9) and (11). Install the plugs to fuel filter assemblies (10) and (12). Refer to Operation and Maintenance Manual, Fuel Filter - Replace for more information. 3. Connect hose assemblies (3), (5), (7) and (8). 4. Connect harness assembly (1) to fuel temperature sensor (2). Slide the locking tab into the locked position. 5. Turn the fuel supply to the ON position. 6. Remove the air from the system. Refer to Systems Operation, Testing and Adjusting, Fuel System - Prime. i Fuel Transfer Pump - Remove Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates. Illustration 7 g Disconnect hose assemblies (2) and (3) from fuel transfer pump (1). Plug the open hose assemblies. 4. Remove bolts (4) and remove fuel transfer pump (1). 5. Remove the O-ring seal from fuel transfer pump (1). i Fuel Transfer Pump - Install 1. Ensure that the fuel transfer pump is clean and free from damage. 1. Turn the fuel supply to the OFF position. 2. Place a suitable container below the fuel transfer pump in order to catch any fuel that might be spilled. Illustration 8 g Lubricate a new O-ring seal with clean engine oil. Install the O-ring seal to fuel transfer pump (1).

8 8 KENR Position fuel transfer pump (1) on pump drive (5). Note: Ensure that the splines on the shaft of the fuel transfer pump are correctly engaged into the pump drive. 4. Install bolts (4). Tighten the bolts to a torque of 47 N m (35 lb ft). 5. Removetheplugsfromthehoseassemblies. Connect hose assemblies (2) and (3) to fuel transfer pump (1). 6. Turn the fuel supply to the ON position. 7. Remove the air from the fuel system. Refer to Systems Operation, Testing and Adjusting, Fuel System - Prime. Illustration 9 g Disconnect harness assembly (1) from electronic unit injector (2). Electronic Unit Injector - Remove i Remove valve bridges (3). If the injector hold down bolt is loose during the removal procedure, inspect the injector bore for wear and debris. Replace the clamp and spacer. Table 1 Tool Part Number Part Description Qty A Pry Bar 1 Start By: a. Remove the rocker arms and the rocker arm shaft. Refer to Disassembly and Assembly, Rocker Arm and Shaft - Remove. 1. Turn the fuel supply to the OFF position. Illustration 10 g Remove bolts (8) and washers (9). Remove harness assembly (1) and support bracket (7) as a unit. 5. Remove bolt (4) and spacer (5). 6. Place an identification mark on electronic unit injector (2) for installation purposes. Each electronic unit injector must be reinstalled in the original location in the cylinder head.

9 KENR i Electronic Unit Injector - Install Illustration 11 g Use Tooling (A) to pry beneath the base and free electronic unit injector (2). 8. Remove electronic unit injector (2) and clamp (6) from the cylinder head. Table 2 Tool B Part Number Part Description Qty GE50028 Vacuum Pump 1 GE50046 FluidSamplingBottle 1 GE50030 Tube 7.9 mm (0.31 inch) OD C - Large Bore Brush 1 D Surface Reconditioning Pad E Torque Wrench Use Tooling (D) to clean the carbon deposit from the inside of the electronic unit injector sleeve. Illustration 12 g Remove O-ring seals (11) and (12) from electronic unit injector (2). 2. Use Tooling (B) to remove the fuel and oil from the cylinder. Evacuate as much fuel and oil as possible from the cylinder before installing the electronic unit injector. Several evacuations may be necessary. Illustration 13 g Ensure that seat area (X) on the electronic unit injector is clean and free carbon. 4. Install new O-ring seals (11) and (12) on the electronic unit injector. Lubricate the O-ring seals with clean engine oil.

10 10 KENR Install a new O-ring seal (13) on the electronic unit injector. Note: O-ring seal (13) should be installed dry. If a replacement electronic unit injector is installed, the calibration code must be programmed into the electronic control module. Refer to Troubleshooting Guide, Injector Trim File for more information. Note: Ensure that used valve bridges are reinstalled in the original location and the original orientation. Do not interchange the location or the orientation of used valve bridges. 11. Install the rocker arms and the rocker arm shaft. Refer to Disassembly and Assembly, Rocker Arm and Shaft - Install. 12. Turn the fuel supply to the ON position. 13. Remove the air from the fuel system. Refer to Systems Operation, Testing and Adjusting, Fuel System - Prime. i Electronic Unit Injector Sleeve -Remove Illustration 14 g Install clamp (6) to electronic unit injector (2). Install electronic unit injector (2) into the original location in the cylinder head. 7. Install spacer (5) and bolt (4). Tighten bolt (4) to a torque of 55 N m (41 lb ft). Table 3 Tool Part Number Part Description Qty A GE50021 Injector Sleeve Tool 1 Start By: a. Remove the electronic unit injectors. Refer to Disassembly and Assembly, Electronic Unit Injector - Remove. Illustration 15 g Drain the coolant from the engine. Refer to Operation and Maintenance Manual, Cooling System Coolant - Change. 8. Install harness assembly (1) and support bracket (7) as a unit. Install bolts (8) and washers (9). Tighten bolts (8) to a torque of 105 N m (77 lb ft). 9. Connect harness assembly (1) to electronic unit injector (2). Use Tooling (E) to tighten the nuts to a torque of 2.5 N m (22 lb in). 10. Install bridge assemblies (3) in the respective locations.

11 KENR Ensure that the electronic unit injector sleeve and the cylinder head bore are completely free of oil, dirt, and sealant debris. Illustration 16 g Install Tooling (A) in electronic unit injector sleeve (1). 3. Tighten the nut on Tooling (A) until the electronic unit injector sleeve is pulled free of the cylinder head. 4. Remove O-ring seals (2) and O-ring seal (3) from electronic unit injector sleeve (1). i Electronic Unit Injector Sleeve -Install Table 4 Tool Part Number Part Description Qty A GE50021 Injector Sleeve Tool 1 B GE50023 Tapered Brush 1 GE50024 Small Bore Brush 1 GE50022 End Brush 1 C CV60893 Retaining Compound 1 1. Use Tooling (B) to clean the bore in the cylinder head for the electronic unit injector sleeve. Illustration 17 g Install new O-ring seals (2) and (3) to electronic unit injector sleeve (1). Note: Do not apply Tooling (C) to the cylinder head surfaces. Apply Tooling (C) to the electronic unit injector sleeve only. 3. Apply a small continuous bead of Tooling (C) to surface (X) of electronic unit injector sleeve (1). 4. Lubricate O-ring seals (2) with clean engine oil. 5. Position Tooling (A) and the electronic unit injector sleeveinthe cylinder head. Use care not to damage the O-ring seals on the electronic unit injector sleeve. 6. Use Tooling (A) to install electronic unit injector sleeve (1) in the cylinder head. Note: Ensure that the electronic unit injector sleeve is properly seated in the cylinder head. 7. Remove Tooling (A). Use a clean towel and remove excess Tooling (C). 8. Fill the cooling system with coolant. Refer to Operation and Maintenance, Refill Capacities for the cooling system capacity. End By: a. Install the electronic unit injectors. Refer to Disassembly and Assembly, Electronic Unit Injector -Install.

12 12 KENR6232 Turbocharger - Remove i Start By: a. Remove the exhaust elbow. Refer to Disassembly and Assembly, Exhaust Elbow - Remove and Install. Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates. 1. Disconnect the air hoses for the turbocharger inlet and for the turbocharger outlet. Illustration 18 g Follow Steps 2.a through 2.c in order to remove the tube assembly (7) for the oil feed. a. Remove tube clamp (9) that secures tube assembly (7) to tube assembly (8). Note the position of the clamp. b. Disconnect tube assembly (7) from the engine oil filter base. c. Remove bolts (3). Remove tube assembly (7) and joint (2) from turbocharger (1). 3. Follow Steps 3 through 3.c in order to remove the tube assembly (8) for the oil drain. a. Remove bolts (6).

13 KENR b. Remove tube assembly (8) and joint (5). c. Remove O-ring seal (10) from tube assembly (8). 4. Attach a suitable lifting device to turbocharger (1). The weight of the turbocharger is approximately 30 kg (66 lb). 5. Remove the fasteners for the turbocharger. Use the lifting device to remove turbocharger (1) from the exhaust manifold. Remove gasket (4). Turbocharger - Install i Table 5 Tool Part Number Part Description A CV60889 Anti-Seize Compound 1 Qty Illustration 19 g Clean the mating surfaces of the exhaust manifold. Position a new gasket (4) on the exhaust manifold. 2. Attach a suitable lifting device to turbocharger (1). The weight of turbocharger is approximately 30 kg (66 lb). Use the lifting device to install turbocharger (1) onto the exhaust manifold. 3. Apply Tooling (A) to the threads of the exhaust manifold bolts. Install the bolts and install locknuts finger tight. 4. Install a new O-ring seal (10) to tube assembly (8). Install tube assembly (7) and new joint (5). Install bolts (6) finger tight. 5. Install tube assembly (7) and a new joint (2). Install bolts (3) finger tight. Connect the lower end of tube assembly (7) to the engine oil filter base.

14 14 KENR Install tube clamp (9) to tube assembly (7) to tube assembly (8). Note: Ensure that the clamp is installed in the correct position. 7. Tighten the fasteners for the turbocharger to a torque of 55 N m (41 lb ft). 8. Tighten the bolts for tube assemblies (7) and (8) to a torque of 47 N m(35lbft). 9. Connect the air hoses for the turbocharger inlet and for the turbocharger outlet. i Exhaust Manifold - Remove and Install 5. If necessary, remove the taperlock studs from the cylinder head. Table 6 Tool Part Number Part Description Qty A CV60889 Anti-Seize Compound - 1. Install the taperlock studs in the cylinder head and tightentoatorqueof35n m(26lbft). Start By: a. Remove the turbocharger. Refer to Disassembly and Assembly, Turbocharger - Remove. b. Remove the water temperature regulator housing. Refer to Disassembly and Assembly, Water Temperature Regulator Housing - Remove and Install. Illustration 21 g Assemble exhaust manifolds (4), (5) and (6). 3. Install the exhaust manifold gaskets onto the taperlock studs. 4. Install the assembly of the exhaust manifolds on the taperlock studs. Note: Ensure that the holes in exhaust manifolds are centralized with the taperlock studs. Illustration 20 g Remove locknuts (3), washers (2) and spacers (1). 5. Apply Tooling (A) to the threads of the taperlock studs. Install spacers (1), washers (2) and locknuts (3). 2. Remove exhaust manifolds (4), (5) and (6). Note: Remove manifolds as one assembly. 3. Remove the exhaust manifold gaskets. 4. Remove exhaust manifolds (4) and (6) from exhaust manifold (5). Illustration 22 g

15 KENR Tighten the locknuts in a numerical sequence that is shown in Illustration 22. Tighten the locknuts to atorqueof38n m(28lbft). End By: a. Install the water temperature regulator housing. Refer to Disassembly and Assembly, Water Temperature Regulator Housing - Remove and Install. s b. Install the turbocharger. Refer to Disassembly and Assembly, Turbocharger - Install. i Exhaust Elbow - Remove and Install Illustration 24 g Thoroughly clean the exhaust elbow and the outlet of the turbocharger. Inspect the components for wear or damage. Replace any components that are worn or damaged. 2. Position clamp (1) and install the exhaust elbow to the turbocharger. Ensure correct orientation of thebandclamp. 3. Tighten the allen head bolt to a torque of 13.5 N m (10 lb ft). i Inlet and Exhaust Valve Springs - Remove and Install Illustration 23 g Use an allen wrench in order to loosen clamp (1) that secures the exhaust elbow. 2. Remove the exhaust elbow and the clamp from the turbocharger. Table 7 Tool Part Number Part Description Qty A CH11148 Engine Turning Tool 1 B GE50026 Valve Spring Compressor 1

16 16 KENR6232 Start By: a. Remove the electronic unit injectors. Refer to Disassembly and Assembly, Electronic Unit Injector-Remove. Note: The following procedure should be adopted in order to remove the valve springs when the cylinder head is installed to the engine. Refer to Disassembly and Assembly Manual, Inlet and Exhaust Valves - Remove and Install for the procedure to remove the valve springs from a cylinder head that has been removed from the engine. 1. Use Tooling (A) to position the appropriate piston at the top center position before the valve spring is removed. Illustration 26 g Note: Failure to ensure that the piston is at the top center position may allow the valve to drop into the cylinder bore. Do not turn the crankshaft while the valve springs are removed. Note: Valve springs must be replaced in pairs for the inlet valves or the exhaust valves of each cylinder. If all valve springs require replacement the procedure can be carried out on two cylinders at the same time. The procedure can be carried out on the following pairsofcylinders.1with6,2with5,and3with4. Ensure that all of the valve springs are installed before changing from one pair of cylinders to another pair of cylinders. Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force. 2. Install Tooling (B) in the electronic unit injector sleeve. Secure Tooling (B) with unit injector clamp (1). 3. Tighten the nut until valve keepers (3) are loose on valves (2). 4. Remove valve keepers (3). Illustration 25 g Loosen the nut in order to release the pressure on Tooling (B). Remove unit injector clamp (1). Carefully remove Tooling (B). 6. Remove valve rotators (4). 7. Remove outer valve springs (6) and inner valve springs (5). 8. Remove washers (7) from the valve guide.

17 KENR Table 8 Tool Part Number Part Description Qty B GE50026 Valve Spring Compressor 1 1. Inspect the valve springs for damage and for the correct length. Refer to Specifications Manual, Cylinder Head Valves. 2. Lubricate the valve stems with clean engine oil. The valve spring keepers can be thrown from the valve when the valve spring compressor is released. Ensure that the valve spring keepers are properly installed on the valve stem. To help prevent personal injury, keep away from the front of the valve spring keepers and valve springs during the installation of the valves. 6. Use Tooling (B) to compress the valve springs. Install valve keepers (3). 7. Loosen the nut in order to release the pressure on Tooling (B). Remove unit injector clamp (1). Carefully remove Tooling (B). 8. Lightly strike the top of the valve with a soft faced hammer in order to ensure that valve keepers (2) are properly installed. End By: a. Install the electronic unit injectors. Refer to Disassembly and Assembly, Electronic Unit Injector - Install. i Inlet and Exhaust Valves - Remove and Install Illustration 27 g Table 9 Tool Part Number Part Description Qty A - Valve Spring Compressor 1 Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment. 3. Install washers (7). 4. Install inner valve springs (5) and outer valve springs (6). Start By: a. Remove the cylinder head. Refer to Disassembly and Assembly, Cylinder Head - Remove. 5. Position valve rotators (4) on the valve springs.

18 18 KENR6232 Table 10 Tool Part Number Part Description Qty A - Valve Spring Compressor B GE50027 Seal Installer Inspect the valve springs for damage and for the correct length. Refer to Specifications Manual, Cylinder Head Valves. Note: Valve springs must be replaced in pairs for the inlet valve or the exhaust valve of each cylinder. Illustration 28 g Inspect the valves. Refer to Specifications, Cylinder Head Valves for additional information on the inlet and exhaust valves. 3. Use Tooling (B) in order to install new valve stem seals onto the valve guides. Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Note: The outer face of the valve guide must be clean and dry before installing the valve stem seal. 4. Lubricate the valves with clean engine oil. Install the valves in the cylinder head. Follow the recommended procedure and use all recommended tooling to release the spring force. 1. Install Tooling (A) and compress the valve springs. Remove valve keepers (2) from valve (1). 2. Carefully remove Tooling (A) from valve (1). 3. Remove valve rotator (3). 4. Remove outer valve spring (5) and inner valve spring (4) from valve (1). 5. Remove washer (6) and valve (1) from the valve guide. 6. Remove the valve stem seal.

19 KENR Carefully remove Tooling (A). Lightly strike the top of the valve with asoftfacedhammerinorder to ensure that valve keepers (2) are properly installed. End By: a. Install the cylinder head. Refer to Disassembly and Assembly, Cylinder Head - Install. i Inlet and Exhaust Valve Guides - Remove and Install Table 11 Tool Part Number Part Description Qty A GE50043 Valve Guide Tool 1 Illustration 29 g Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment. Start By: a. Remove the inlet and exhaust valves. Refer to Disassembly and Assembly, Inlet and Exhaust Valves - Remove and Install. 5. Install washer (6). 6. Install inner valve spring (4) and outer valve spring (5). 7. Position valve rotator (3) on the valve springs. 8. Use Tooling (A) to compress valve springs. Install valve keepers (2). The valve spring keepers can be thrown from the valve when the valve spring compressor is released. Ensure that the valve spring keepers are properly installed on the valve stem. To help prevent personal injury, keep away from the front of the valve spring keepers and valve springs during the installation of the valves. Illustration 30 g Use Tooling (A) and a hammer to remove valve guide (1) from the cylinder head.

20 20 KENR6232 Table 12 Tool Part Number Part Description Qty A GE50043 Valve Guide Tool 1 B GE50044 Valve Guide Sleeve 1 Engine Oil Filter Base - Remove i Start By: a. Remove the oil cooler. Refer to Disassembly and Assembly, Engine Oil Cooler - Remove. Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates. Illustration 31 g Lubricate the bores for the valve guides with clean engine oil. 2. Install valve guide (1) in the cylinder head with Tooling (A) and Tooling (B). Note: Tooling (B) must be used in order to install the valve guide to the correct height. Height to top of valve guide from cylinder head surface ± 0.50 mm (1.378 ± inch) Note: For more information, refer to Specifications, Cylinder Head Valves. End By: a. Install the inlet and exhaust valves. Refer to Disassembly and Assembly, Inlet and Exhaust Valves - Remove and Install. Illustration 32 g Use a suitable tool with a 1/2" square drive in order to remove engine oil filter (5). Remove the O-ring seal. Remove the filter element. Refer to Operation and Maintenance Manual, Engine Oil - Change for more information.

21 KENR Disconnect tube assembly (1). 3. Remove bolts (2) and bolts (4). 4. Remove engine oil filter base (3). Remove the O-ring seals from the engine oil filter base. Engine Oil Filter Base - Disassemble i Disassembly Procedure Start By: a. Remove the engine oil filter base. Refer to Disassembly and Assembly, Engine Oil Filter Base - Remove. Illustration 33 g Remove bolts (3). Remove elbow (1) from engine oil filter base (2). Remove the O-ring seals from the elbow. 2. Remove plug (5). Remove the O-ring seal from plug (5). 3. Remove spring (7). Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. 4. Remove plunger (6). 5. If necessary, remove oil sampling valve (4) from the engine oil filter base. remove the O-ring seal from the oil sampling valve. Follow the recommended procedure and use all recommended tooling to release the spring force. Engine Oil Filter Base - Assemble i Assembly Procedure

22 22 KENR6232 Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment. i Engine Oil Filter Base - Install Illustration 34 g Inspect the components for wear or damage. Replace any components that are worn or damaged. 2. Lubricate plunger (6) and spring (7) with clean engine oil. Install the plunger and the spring into engine oil filter base (2). 3. Install a new O-ring seal to plug (5). Install plug (5) to engine oil filter base (2). Tighten plug (5) to a torque of 100 N m (74 lb ft). 4. Install new O-ring seals to elbow (1). Position elbow (1) on the engine oil filter base and install bolts (3). 5. If necessary, install a new O-ring seal to oil sampling valve (4). Install oil sampling valve (4) to engine oil filter base (2). Tighten the oil sampling valvetoatorqueof24n m(18lbft). Illustration 35 g Install new O-ring seals to engine oil filter base (3). 2. Position engine oil filter base (3) on the engine and install bolts (2) and bolts (4). Tighten the bolts to a torque of 47 N m (35 lb ft). 3. Connect tube assembly (1). 4. Install the oil cooler. Refer to Disassembly and Assembly, Engine Oil Cooler - Install. 5. Install a new O-ring seal to engine oil filter (5). Install engine oil filter (5) to engine oil filter base (3). Refer to Operation and Maintenance Manual, Engine Oil - Change for more information. End By: a. Install the engine oil filter base. Refer to Disassembly and Assembly, Engine Oil Filter Base - Install.

23 KENR i Engine Oil Cooler - Remove Engine Oil Cooler - Install i Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates. 1. Drain the coolant from the cooling system into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, Cooling System Coolant - Change. Table 13 Tool Part Number Part Description Qty A POWERPART Rubber Grease - Illustration 36 g Remove bolts (1). Remove outlet bonnet (3) from the cylinder block and from the engine oil cooler. Remove joint (2) and O-ring seal (7) from the outlet bonnet. 3. Remove bolts (8). Rotate core assembly (4) and slide the core assembly toward the rear of the engine in order to remove the core assembly from the engine oil filter base. Remove O-ring seals (9) from the engine oil filter base. 4. Remove bolts (11). Remove oil cooler bonnet (5) from the water pump. Remove joint (6) and O-ring seal (10) from the oil cooler bonnet. Illustration 37 g Install a new O-ring seal (10) to oil cooler bonnet (5). Apply Tooling (A) to the O-ring seal. Install joint (6) to oil cooler bonnet (5). Position the oil cooler bonnet on the water pump and install bolts (11). Tighten the bolts finger tight. 2. Install two new O-ring seals (9) to the engine oil filter base. 3. Slide core assembly (4) toward the front of the engine. Rotate the core assembly into position. Install bolts (8). Tighten the bolts finger tight. 4. Install a new O-ring seal (7) to outlet bonnet (3). Apply Tooling (A) to the O-ring seal. Install joint (2) to outlet bonnet (3). Position outlet bonnet (3) on the core assembly and install bolts (1). Tighten the bolts finger tight. 5. Tighten bolts (8), (1) and (11) to a torque of 47 N m (35 lb ft).

24 24 KENR Fill the cooling system. Refer to Operation and Maintenance Manual, Cooling System Coolant - Change. 7. Check the level of the engine lubricating oil. Refer to Operation and Maintenance Manual, Engine Oil Level - Check. i Engine Oil Pump - Remove Start By: a. Remove the engine oil pan. Refer to Disassembly and Assembly, Engine Oil Pan - Remove and Install. Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates. 2. Remove the fasteners and remove the assembly of the suction pipe (2). Remove the O-ring seal from the tube assembly. 3. Remove bolts (5) and remove engine oil pump (1) from the cylinder block. 4. If necessary, remove bolts (4) and remove underframe assembly (3). i Engine Oil Pump - Disassemble Disassembly Procedure Table 14 Tool Part Number Part Description Qty A - Puller (Three Leg) 1 Start By: a. Remove the engine oil pump. Refer to Disassembly and Assembly, Engine Oil Pump - Remove. Illustration 38 Typical example g Remove the fasteners and remove tube assembly (6). Remove the O-ring seal from the tube assembly. Illustration 39 g

25 KENR Remove the bolt that holds drive gear (1) to the shaftofengineoil pump (2). Use Tooling (A) to remove the drive gear from the shaft. Remove the key from the shaft. Illustration 41 g Illustration 40 g Personal injury can result from parts and/or covers under spring pressure. 1. Useapressandasuitabletooltoinstallsleeve bearings (4) in pump body (3). The bearing joint shouldbe30±15degreesfromthecenterlineof the two bearing bores. Install the sleeve bearings so the sleeve bearings are even with the outside of the pump body. Spring force will be released when covers are removed. Be prepared to hold spring loaded covers as the bolts are loosened. 2. Remove bolts (8). Remove retainer (5), spring (6), and relief plunger (7) from pump body (3). 3. Remove bolts (9) and cover (10). 4. Remove idler gear (12) and drive gear (13) from the pump body. 5. Use a suitable tool to remove sleeve bearings (4) from the pump body. 6. Use a suitable tool to remove sleeve bearings (11) from the cover. Illustration 42 g Useapress and a suitable tool to install sleeve bearings (11) in cover (10). The bearing joint shouldbe30±15degreesfromthecenterlineof the two bearing bores. Install the sleeve bearings so the sleeve bearings are even with the outside of the cover. i Engine Oil Pump - Assemble Assembly Procedure Illustration 43 g

26 26 KENR6232 Improper assembly of parts that are spring loaded can cause bodily injury. Engine Oil Pump - Install i To prevent possible injury, follow the established assembly procedure and wear protective equipment. 3. Lubricate the idler gear and the drive gear with clean engine oil. Lubricate sleeve bearings (4) with clean engine oil. Install idler gear (12) and drive gear (13) in pump body (3). 4. Lubricate sleeve bearings (11) with clean engine oil. Install cover (10). Install bolts (9). Note: The engine oil pump must turn freely after assembly. Turn the engine oil pump by hand. Reposition cover (10) if the engine oil pump does not turn freely. 5. Install relief plunger (7), spring (6), retainer (5), and bolts (8). 6. Install the key on the shaft. Illustration 45 Typical example g Position underframe assembly (3) on the cylinder block. Install bolts (4). Tighten the bolts to a torque of 47 N m (35 lb ft). 2. Position engine oil pump (1) on the dowels in the cylinder block. Install bolts (5). Tighten the bolts to a torque of 47 N m (35 lb ft). Illustration 44 g Install drive gear (1) on the shaft of engine oil pump (2). Install bolt (14). Tighten the bolt to a torque of 55 N m (41 lb ft). End By: a. Install the engine oil pump. Refer to Disassembly and Assembly, Engine Oil Pump - Install. Note: Ensurethattheengineoilpumpisseatedon the dowels before the bolts are tightened. 3. Install a new O-ring seal to tube assembly (6). Lubricate the bore in the engine oil pump with clean engine oil. Install tube assembly (6). Install the bolts that secure the tube assembly. Tighten the bolts to a torque of 47 N m (35 lb ft). 4. Install a new O-ring seal to the assembly of suction pipe (2). Lubricate the bore in the engine oil pump with clean engine oil. Install the assembly ofsuctionpipe(2).installtheboltsandwashers that secure the tube assembly. Tighten the bolts to a torque of 47 N m (35 lb ft). End By: a. Install the engine oil pan. Refer to Disassembly and Assembly, Engine Oil Pan - Remove and Install.

27 KENR Water Pump - Remove i Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates. 1. Drain the coolant from the cooling system into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, Cooling System Coolant - Change. Illustration 46 g Remove bolts (2) from water temperature regulator housing (1). Remove water temperature regulator housing (1) and pipe (3) as a unit. Remove the O-ring seals from the water temperature regulator housing and the pipe. 3. Remove bolts (5). Remove water pump cover (4) from water pump (8). Remove the O-ring seal from the water pump cover. 4. Remove bolts (7). Remove oil cooler bonnet (6) from the engine oil cooler. Remove the joint and the O-ring seal from the oil cooler bonnet. 5. Remove the belt tightener. Refer to Disassembly and Assembly, Belt Tightener - Remove. 6. Attach a suitable lifting device to water pump (8). Support the weight of the water pump. The water pump weighs approximately 18.3 kg (40 lb). 7. Remove bolts (9). 8. Use the lifting device in order to remove water pump (8) from the front housing. Remove the O-ring seal from the water pump.

28 28 KENR6232 Water Pump - Install i Use a suitable lifting device in order to position water pump (8) on the front housing. The water pump weighs approximately 18.3 kg (40 lb). Table 15 Tool Part Number Part Description Qty A POWERPART Rubber Grease 1 3. Install bolts (9). Tighten the bolts to a torque of 47 N m (35 lb ft). 4. Install the belt tightener. Refer to Disassembly and Assembly, Belt Tightener - Install. 5. Install a new O-ring seal on oil cooler bonnet (6). Apply Tooling (A) to the O-ring seal. Position the joint and install oil cooler bonnet (6) to the engine oil cooler. Install bolts (7). Tighten the bolts to a torque of 47 N m (35 lb ft). 6. Install a new O-ring seal to water pump cover (4). Position water pump cover (4) on water pump (8) and install bolts (5). Tighten the bolts to a torque of 47 N m (35 lb ft). 7. Install new O-ring seals to pipe (3). Apply Tooling (A) to the O-ring seals. Install the pipe in the water temperature regulator housing (1). Install a new O-ring seal to water temperature regulator housing (1). 8. Insert pipe (3) into water pump cover (4). Install the assembly of the water temperature regulator housing and pipe as a unit. Install bolts (2). Tighten the bolts to a torque of 47 N m (35 lb ft). 9. Fill the cooling system. Refer to Operation and Maintenance Manual, Cooling System Coolant - Change. i Water Temperature Regulator Housing - Remove and Install Illustration 47 g Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates. 1. Install a new O-ring seal to water pump (8).

29 KENR Drain the coolant from the cooling system into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, Cooling System Coolant - Change. Illustration 49 g Remove water temperature regulator housing (1) from housing manifold (2). Remove O-ring seal (7) and O-ring seal (6) from the housing manifold. 5. Remove water temperature regulators (8). 6. Remove lip seal (10). Illustration 48 Typical example g Slide the locking tab into the unlocked position and disconnect the harness assembly from coolant temperature sensor (5). 3. Remove bolts (3). Remove pipe (4), water temperature regulator housing (1), and housing manifold (2). 7. Remove pipe (4) from the water temperature regulator housing. Remove O-ring seals (9) from pipe (4). 8. If necessary, remove coolant temperature sensor (5). Refer to Disassembly and Assembly, Coolant Temperature Sensor - Remove and Install. Table 16 Tool Part Number Part Description Qty A Seal Installer 1 B POWERPART Rubber Grease 1

30 30 KENR Loosely install bolts (3) to water temperature regulator housing (1) and housing manifold (2). Position water temperature regulator housing (1) and housing manifold (2) onto pipe (4). Tighten the bolts to a torqueof47n m(35lbft). 6. If necessary, install coolant temperature sensor (5). Refer to Disassembly and Assembly, Coolant Temperature Sensor - Remove and Install. 7. Connect the harness assembly to coolant temperature sensor (5). Slide the locking tab into thelockedposition. 8. Fill the cooling system. Refer to Operation and Maintenance Manual, Cooling System Coolant - Change. Illustration 50 g Use Tooling (A) to install lip seals (10) into water temperature regulator housing (1). 2. Install new O-ring seals (9) onto pipe (4). Apply Tooling(B)totheO-ringseals.Installpipe(4)to the water pump. 3. Install O-ring seal (6) and O-ring seal (7) to housing manifold (2). 4. Install water temperature regulators (8) into the water temperature regulator housing (1). Engine Support (Front) - Remove and Install Table 17 i Tool Part Number Part Description Qty A - Start By: Guide Stud (1/2-13 UNC by6inch) 2 a. Remove the assembly of the vibration damper and the crankshaft pulley. Refer to Disassembly and Assembly, Vibration Damper and Pulley - Remove and Install. 1. Support the front of the engine. Illustration 51 Typical example g Illustration 52 g

31 KENR Remove bolts (1) and install Tooling (A). Remove the remaining bolts. 3. Remove engine support (2) from the cylinder block. The weight of engine support (2) is approximately 33.5 kg (74 lb). Table 18 Tool Part Number Part Description Qty A - Guide Stud (1/2-13 UNC by 6 inch) 1. Support the front of the engine. 2 End By: a. Install the assembly of the vibration damper and the crankshaft pulley. Refer to Disassembly and Assembly, Vibration Damper and Pulley - Remove and Install. Flywheel - Remove Table 19 Tool A - i Part Number Part Description Qty Guide Stud 5/8-18 by 8 inch 2 Start By: a. Remove the electric starting motor. Refer to Disassembly and Assembly, Electric Starting Motor - Remove and Install. Illustration 53 g Position engine support (2) on Tooling (A). The weight of engine support (2) is approximately 33.5 kg (74 lb). 3. Install bolts (1) finger tight. Remove Tooling (A) and install the remaining bolts. Illustration 55 Typical example g Illustration 54 Tightening sequence g Install bolts (1). Tighten the bolts to a torque of 105 N m (77 lb ft) in the order that is shown in Illustration Use a suitable tool to lock the flywheel. Loosen bolts (1). 2. Attach a suitable lifting device to flywheel (1). Support the weight of the flywheel. The weight of flywheel (2) is approximately 130 kg (286 lb). 3. Remove two bolts (1). Install Tooling (A).

32 32 KENR Remove the remaining bolts (1). Use the lifting device in order to remove flywheel (2). Illustration 57 g Illustration 56 Typical example g Inspect flywheel (2) and ring gear (3) for wear or damage. Replace any components that are worn or damaged. 6. To remove the flywheel ring gear, follow Steps 6.a and 6.b. a. Place the flywheel assembly on a suitable support. Note: Identify the orientation of the teeth on the flywheel ring gear. b. Use a hammer and a punch in order to remove ring gear (3) from flywheel (2). Flywheel - Install Table 20 i Tool Part Number Part Description Qty A - Guide Stud 5/8-18 by 8 inch 2 Always wear protective gloves when handling parts that have been heated. 1. If the flywheel ring gear was removed, follow Steps 1.a through 1.c in order to install a new ring gear to the flywheel. a. Identify the orientation of the teeth on the new ring gear (3). Note: The chamfered side of the ring gear teeth must face toward the starting motor when the flywheel is installed. This will ensure the correct engagement of the starting motor. b. Heat flywheel ring gear (3) in an oven to a maximum temperature of 316 C (600 F) prior to installation. Note: Do not use a torch to heat the ring gear. c. Ensure that the orientation of ring gear (3) is correct and quickly install the ring gear onto flywheel (2). 2. Inspect the crankshaft rear seal for leaks. If there are any oil leaks, replace the crankshaft rear seal. Refer to Disassembly and Assembly, Crankshaft Rear Seal - Remove.